Bar Heating Induction Furnace

The induction furnace for bar heating is well understood from the literal meaning, that is, the medium frequency furnace for heating bar. However, the connotation is not simple, and the bar heating process is relatively complex. Why do we think the bar heating induction furnace is complex? Let's give you a detailed introduction.

1. Differences between bar heating induction furnace and other heating furnaces

1) The heating principle is different

Most of the previous bar heating furnaces used coal, gas, oil, and resistance heating. The heating principle is radiation heating, that is, the furnace is heated to a certain temperature and transmitted to the heating bar through heat radiation, so that the bar temperature can reach the process heating temperature; The medium frequency furnace for bar heating adopts the principle of electromagnetic induction heating, which cuts the metal through the magnetic line of force, forms a vortex in the bar, the current flows, and the bar heats itself, so as to achieve the purpose of heating the bar. In other words, in the past, the heating furnace heated the bar through heat conduction, but now the heating furnace of Haishan electric furnace generates eddy current through the magnetic line of force, making the bar heat itself.

2) The heating speed is different

The previous bar heating furnace had to raise the furnace temperature to the process temperature for a long time; Now, the bar heating of electric furnace, the instantaneous electromagnetic induction of the medium frequency furnace can make the bar reach the temperature required by the heating process, which does not need the preliminary preparation for furnace temperature rise and reduces the labor intensity.

3) Meet the environmental protection requirements

The previous heating furnace will produce a large amount of smoke and dust in the combustion of coal, oil and gas, while the bar heating induction furnace makes the bar heat itself and will not produce smoke and dust, which meets the environmental protection requirements. It belongs to the heating industry and advocates the development of water temperature heating equipment.

4) The utilization rate of bar material is different

In the past, the heating time of heating furnace was long, the oxidation burning loss was large, and the utilization rate of bar oxide scale was reduced; Nowadays, the medium frequency furnace for bar heating of Haishan electric furnace has fast heating speed, reduced oxidation burning loss, greatly reduced relative oxide scale and greatly improved bar utilization.

2. Basic parameters of induction furnace for bar heating

1) The induction furnace for bar heating is expressed by heating power and heating frequency: 

the heating power is 100kW -- 20000KW; The heating frequency is different according to the outer diameter of the bar, and the frequency range is 50Hz --- 8000Hz:

2) The medium frequency furnace for bar heating is mainly composed of the thyristor control circuit, and the model is expressed as: 

KGPS power / frequency; 

The heating furnace head is expressed as GTR - bar diameter; 

KGPS is used together with GTR and cannot be used alone.

3) The material of bar heating induction furnace heating bar is: alloy steel, alloy aluminum, stainless steel, alloy copper, titanium alloy and other metal materials

4) The heating temperature of medium frequency furnace for bar heating can be heated at different temperatures according to the heating process requirements. Generally speaking, the forging heating temperature is 1200 ℃; The quenching heating temperature of bar material is between 700 ℃ - 1000 ℃; The tempering heating temperature of bar material is between 450 ℃ - 600 ℃; Warm forging temperature is between 800 ℃ - 9000 ℃;

3. Auxiliary equipment of induction furnace for bar heating

Bar heating medium frequency furnace is commonly used in bar forging heating industry and bar quenching and tempering heating industry. Supporting auxiliary equipment can realize the automation of heating production line. These auxiliary equipment include automatic feeder, roller conveyor, cylinder pushing, temperature detection device, PLC control system, discharge system, hsbl cooling system, power supply device, etc, The main purpose is to realize the intellectualization of bar heating medium frequency furnace production line, and it is also the main force of intelligent factory construction at present.

To sum up, the bar heating medium induction furnace has obvious heating characteristics, is deeply loved by people in the heating industry, and is also the mainstream equipment in the bar heating industry at present.

If you are interested in bar heating induction furnace, please mail at marketing2@hanrm.com for your solution.

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Presentation on Electric Arc Furnace (A)

The electric arc furnace is an electric furnace that uses high temperature produced by electrode arc to smelt ore and metal. When the arc is formed by gas discharge, the energy is concentrated and the temperature of the arc zone is above 3000 ℃. For smelting metals, EAF is more flexible than other steelmaking furnaces, which can effectively remove sulfur, phosphorus and other impurities. The furnace temperature is easy to control, and the equipment covers a small area. It is suitable for smelting high-quality alloy steel.

Introduction

Through the metal electrode or nonmetal electrode to produce electric arc heating industrial furnace is called electric arc furnace. According to the form of arc, EAF can be divided into three-phase EAF, consumable EAF, single-phase EAF and resistance EAF. The furnace body of EAF is composed of furnace cover, furnace door, tapping tank and furnace body. The furnace bottom and wall are built with basic refractory or acid refractory.

According to the transformer capacity per ton of furnace capacity, EAF can be divided into ordinary power EAF, high power EAF and ultra-high power EAF. EAF steelmaking is to input electric energy into EAF through graphite electrode, and take the arc between electrode end and charge as heat source for steelmaking. Electric energy is used as the heat source in EAF, and the atmosphere in EAF can be adjusted, which is very beneficial to the smelting of steel grades with more oxidizable elements.

Shortly after the invention of EAF steelmaking, it was used to smelt alloy steel and developed greatly. With the improvement of EAF equipment and smelting technology, the development of electric power industry, the cost of EAF steelmaking is decreasing. Now EAF steelmaking is not only used for the production of alloy steel, but also for the production of ordinary carbon steel. The proportion of its output in the total steel output of major industrial countries is rising.

Development History

In 1888-1892, p.l.t.h é roult developed coal instead of energy by using a high temperature of electrode arc, and invented an arc furnace for direct smelting. At first, the EAF was only used for the production of calcium carbide and ferroalloy, and it was developed to make steel in 1906, and thus the scrap steel could be recycled economically and in scale. The electric energy is converted into heat energy by the arc between the end of the graphite electrode and the charge, and then the furnace charge is melted and the subsequent high-temperature metallurgical reaction is completed. Because it uses electric energy and is easy to adjust the atmosphere in the furnace, it can smelt various kinds of alloy steel including the oxidizable elements.

With the development of power industry, the continuous improvement of process equipment and the improvement of smelting technology, arc furnace is widely used and its production capacity and scale are increasing. The maximum capacity of EAF was 100t in 1930s, 200t in 1950s and 400t in the early 1970s. Especially in the past 50 years, the technical performance of EAF has been gradually improved, and the production cost has decreased significantly. The proportion of EAF steel in developed countries in Europe and America has exceeded 50%. The development of modern EAF smelting technology advances with the times. 

In the 1960s-1970s, the development of ultra-high power supply and related technologies is mainly carried out. HP and UHP are compared with the general power arc furnace (RP). They are mainly divided according to the capacity of transformer per ton of furnace capacity, and there is a trend of higher and higher in recent years. This means that the heat energy of the electric arc furnace is greatly increased in unit time, which makes the melting time significantly shortened, thus improving the production capacity, reducing electrode consumption, reducing heat loss and reducing the power consumption. The result is that the production capacity is increased again, and the cost also decreases greatly. High voltage long arc operation, water-cooled furnace wall, water-cooled furnace cover, foam slag technology, and external heat source melting have been widely used in conjunction with ultra-high power electric arc furnace. Ladle refining and intensified oxygen utilization have also been adopted.

In the 1980s, the development of LF and EBT technology made the modern EAF steelmaking process of EAF smelting and refining outside the furnace mature. It is worth noting that since then, people have paid more attention to the use of secondary combustion and flue gas sensible heat, namely, the preheating of scrap steel. Different preheating methods of scrap produce different types of modern EAFs, including ordinary arc furnaces preheating with basket scrap, flue shaft furnace with supporting claws, double shell arc furnace and Consteel arc furnace. At present, the equipment and production technology of EAF are still in the process of continuous development.

Inquiry about heating furnaces, please mail at marketing2@hanrm.com.

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Factors Affecting Energy Consumption of Intermediate Frequency Furnace

The intermediate frequency furnace has the advantages of high electrical and thermal efficiency, short melting time, power saving, less floor space, lower investment, easy process automation, and production flexibility. Compared with other melting furnaces, such as industrial frequency furnaces, intermediate frequency furnace has lower energy consumption and higher production efficiency. However, the low energy consumption is relative to other equipment. For enterprise production, it is of course to achieve the maximum benefit as the goal and minimize energy consumption. Therefore, it is necessary to increase the production base and reduce the total energy consumption.

To reduce the energy consumption of the intermediate frequency furnace, it is necessary to understand the factors that affect the energy consumption of the intermediate frequency furnace. The main factors affecting the energy consumption of the intermediate frequency furnace are as follows:

1. Power

The power density configuration of the induction furnace. High configuration, fast melting speed and good energy-saving effect. Whether the electric furnace can maintain high power and continuously send power to the furnace will affect the level of energy consumption; the messy arrangement of the power cord of the intermediate frequency furnace will affect the processing capacity of the power supply, resulting in unstable power, low power conversion efficiency, and energy consumption.

2. Melt

The cleanliness of the surface of the charge, if there are 5% impurities, it will consume 5% of the electrical energy to melt these impurities, which will also affect the life of the furnace lining; whether the length of the charge block is appropriate will affect the electric efficiency and melting quality of the electric furnace, generally 200～ 300mm block size is appropriate.

3. Refractory materials

Using a suitable crucible can increase the melting rate. Quartz crucibles are resistant to high temperatures, and when used with intermediate frequency furnaces, the metal materials in the crucible can generate heat by induction heating, which can reduce the consumption of heat transfer.

4. The improper operation causes high energy consumption

The molten metal is overheated, and the furnace is discharged continuously. Not only is it unsafe, but it is also wrong in terms of energy consumption and the melting process. Generally, electric furnace sensors are divided into upper and lower parts. When the molten metal level in the furnace is lower than half of the upper sensor, due to the change of resistance, the upper sensor no longer has induced current to pass, and all are concentrated in the lower sensor, making the lower molten metal overheating, scouring the furnace wall, the life of the furnace lining drops sharply.

Understanding these four major factors that affect the energy consumption of intermediate frequency furnaces and improving them in production can avoid unnecessary consumption, reduce production costs, and improve production efficiency.

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Electric Arc Furnace Steelmaking Process

1. Feeding

The operation of adding molten iron or scrap steel to the electric furnace is the first step of the electric furnace steelmaking operation.

2. Slagging

The operation of adjusting the slag composition, alkalinity, viscosity and reaction ability in steel and iron production. For example, the oxygen blowing operation is to generate slag with sufficient fluidity and alkalinity, which can transfer enough oxygen to the metal surface, so as to reduce the sulfur and phosphorus below the upper limit of the planned steel grade, and the amount of splashing and slag spilling during oxygen blowing should be minimized.

3. Slag discharge

It refers to the slagging operation taken during the smelting process in the electric arc furnace steelmaking according to different smelting conditions and purposes. For example, when single slag method is used for smelting, oxidation slag must be removed at the end of oxidation; when double slag method is used to make reduction slag, the original oxidation slag must be completely released to prevent phosphorus from returning.

4. Molten pool mixing

Supply energy to the molten metal pool to make the molten metal and slag move to improve the kinetic conditions of the metallurgical reaction. The stirring of the molten pool can be achieved by means of gas, mechanical, electromagnetic induction and other methods.

5. Dephosphorization

It’s the chemical reaction to reduce the phosphorus content in molten steel. Phosphorus is one of the harmful impurities in steel. Steel with too much phosphorus, when used at room temperature or lower, is prone to brittleness, which is called "cold brittleness". The higher the carbon content in steel, the more serious the embrittlement caused by phosphorus. Generally, it is stipulated that the phosphorus content of ordinary steel does not exceed 0.045%, and high-quality steel requires less phosphorus.

6. Electric furnace bottom blowing electric furnace bottom blowing

Blow N2, Ar, CO2, CO, CH4, O2 and other gases into the molten pool in the furnace through the nozzle placed at the bottom of the furnace to accelerate the melting and promote the metallurgical reaction process. The use of bottom blowing technology can shorten smelting time, reduce power consumption, improve dephosphorization and desulfurization operations, increase the amount of residual manganese in steel, and increase the yield of metals and alloys. And can make the molten steel composition and temperature more uniform, thereby improving steel quality, reducing costs, and increasing productivity.

7. Melting period

The melting period of steelmaking is mainly for open hearth and electric furnace steelmaking. The melting period of electric arc furnace steelmaking starts from the time of electrifying to the time when all the accompanying materials are melted, and for open hearth steelmaking, it is called melting period from the end of hot metal mixing to the end of furnace burden melting. The task of the melting period is to melt and heat up the charge as soon as possible, and make the slag in the melting period.

8. Oxidation period and decarbonization period

The oxidation period of ordinary power electric arc furnace steelmaking usually refers to the process stage from dissolution of the charge, sampling and analysis to the completion of the oxidation slag. Some think it started from blowing oxygen or adding ore to decarbonize. The main task of the oxidation period is to oxidize the carbon and phosphorus in the molten steel; remove the gas and inclusions; make the molten steel uniformly heated. Decarburization is an important process in the oxidation period. In order to ensure the purity of steel, the amount of decarburization is required to be greater than about 0.2%. With the development of refining technology outside the furnace, most of the oxidation refining of the electric arc furnace is moved to the ladle or refining furnace.

9. Refining period

The steelmaking process uses slagging and other methods to select some elements and compounds that are harmful to the quality of steel into the gas phase or discharge or float into the slag through chemical reactions, so that they are excluded from the molten steel. The continuous casting machine discharges the billet.

10. Restoration period

In ordinary power electric arc furnace steelmaking operations, the period from the completion of slagging at the end of oxidation to tapping is usually called the reduction period. Its main task is to create reduced slag for diffusion, deoxidation, desulfurization, control of chemical composition and temperature adjustment. High-power and ultra-power electric arc furnace steelmaking operations have canceled the reduction period.

11. Refining outside the furnace

The steelmaking process in which the molten steel initially made in a steelmaking furnace (converter, electric furnace, etc.) is transferred to another vessel for refining is also called secondary metallurgy. Therefore, the steelmaking process is divided into two steps: primary smelting and refining. Primary refining: The charge is melted, dephosphorized, decarburized and main alloyed in a furnace with an oxidizing atmosphere. Refining: Degas, deoxidize, desulfurize, remove inclusions and fine-tune the composition in a container of vacuum, inert gas or reducing atmosphere. The advantages of dividing steelmaking into two steps are: it can improve the quality of steel, the steelmaking workshop can shorten the smelting time, simplify the process and reduce the production cost. There are many types of out-of-furnace refining, which can be roughly divided into two types: out-of-furnace refining under atmospheric pressure and out-of-furnace refining under vacuum. According to different treatment methods, it can be divided into ladle processing type furnace refining and ladle refining type furnace refining.

12. Molten steel stirring

The stirring of molten steel during the refining process outside the furnace. It homogenizes the composition and temperature of molten steel and can promote metallurgical reactions. Most metallurgical reaction processes are phase interface reactions, and the diffusion rate of reactants and products is the limiting link of these reactions. When molten steel is in a static state, its metallurgical reaction speed is very slow. For example, it takes 30 to 60 minutes to desulfurize molten steel in an electric furnace; while it takes only 3 to 5 minutes to stir the molten steel in furnace refining. When molten steel is in a static state, the inclusions are removed by floating upwards, and the removal speed is slow; when the molten steel is stirred, the removal speed of the inclusions increases exponentially and is related to the stirring strength, type, and characteristics and concentration of the inclusions.

13. Feeding wire in ladle

Feed the steel ladle with deoxidation, desulfurization and fine-tuning powders, such as Ca-Si powder, or directly fed into aluminum wire, carbon wire, etc., to deep desulfurize, calcium and fine-tune the molten steel into the steel ladle The method of carbon and aluminum components. It also has the function of cleaning molten steel and improving the shape of non-metallic inclusions.



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How to Choose Electric Arc Furnace?

Electric furnace is the abbreviation of an electric arc furnace. It is a kind of process equipment with scrap as the main raw material, some molten iron or pig iron as the additional part, electricity as the main energy and chemical energy as the auxiliary energy for smelting. Because there is no coking, sintering and iron making process in the process flow, it is also called a short process, which is different from the long process of converter smelting.

Due to the characteristics of low greenhouse gas emission and low energy consumption, the short process has been widely concerned by metallurgical workers and has experienced rapid development in the historical development process. At present, the annual output of converter steel accounts for about 2 / 3 of the world's steel output, and that of electric furnace steel accounts for about 1 / 3 of the world's steel output.

Classification of electric furnaces
According to the power supply mode, the electric furnace can be divided into DC electric furnace and AC electric furnace.

Direct current furnace

DC electric furnace uses DC power as the main energy to provide heat source for the furnace. Generally, there is only one anode on the top of the furnace, forming a circuit with the cathode at the bottom of the furnace. It is characterized by very low electrode consumption, generally less than 1kg / ton steel, and stable molten pool. Because only one electrode and molten pool form arc column, the radiation damage to furnace lining is low, the consumption of refractory materials is relatively low, and the damage of water-cooled plate on the furnace wall is relatively small. The disadvantage is that the bottom electrode is relatively complex, there are several forms of water-cooled, conductive bottom type and needle-like distribution in the bottom refractory, but the service life is relatively short, the maintenance cost is high, resulting in high smelting cost. In addition, the rectifier equipment investment is relatively high, resulting in higher one-time investment.

The direct current electric furnace is not the main equipment in the electric furnace plant. In recent years, new progress has been made in the research of the bottom electrode, which basically solves the problem of short bottom life of the bottom electrode furnace. IThe low consumption of the graphite electrode shows a great advantage in smelting cost. It is expected that the DC electric furnace will be put into production in the new round of electric furnace construction.

Alternating current electric arc furnace

The three-phase alternating current furnace has been used in industrial production for more than 100 years. Its equipment is characterized by the use of three-phase alternating current power supply. When the three-phase graphite electrode contacts with scrap steel, an arc is generated under the action of huge current. The high temperature of the arc is used to melt scrap steel and molten steel. Compared with the direct current furnace, because there are three-phase electrodes, the electrode consumption is higher than that of the direct current furnace. The three-phase electrode has a polar circle, which is relatively close to the furnace wall, and the refractory consumption is relatively high, but the furnace bottom is relatively safer and has a long service life. 

At the beginning of this century, the EAF steelmaking technology has made great progress. On the basis of electric energy as the main energy, auxiliary energy and chemical energy have been introduced. With the development of automatic control technology, power input has increased from ordinary power to high power and ultra-high power, consumption has decreased and productivity has increased. In the case of all scrap steel as raw material, the smelting cycle of this furnace is less than 60 minutes, the power consumption is less than 280kwh / ton steel, the electrode consumption is less than 1.2kg/ton steel, and the annual steel output per nominal capacity has exceeded 10000 tons (i.e. the furnace with a nominal capacity of 100 tons, with an annual steel output of more than 1 million tons), the productivity is greatly improved, and at the same time, the process changes have also derived a variety of furnace types. 

  

 
Common type 3 AC electric furnace

Traditional electric furnace
The traditional electric furnace is the early mainstream electric arc furnace. Scrap steel is added from the top of the furnace, that is, the crown block basket is used to open the furnace cover and scrap steel is added. Each furnace needs to be charged twice to three times or more. The power consumption is relatively high, the electrode consumption is high, the noise is large when melting, the amount of flue gas at the moment of charging is large, the overflow is very obvious, the heat loss is large, the capacity of transformer is large, and the impact on the power grid is relatively large. Generally, mining In addition to the three-electrode holes, the fourth hole of the furnace cover is used for dust removal. The dust removal effect is relatively poor. In areas with strict dust and noise requirements, the way of increasing smoke hood for dust removal or building isolation hood, commonly known as doghouse, is used for secondary dust collection and noise collection. The early electric furnaces in China belong to the traditional type. However, the furnace technology is relatively mature, low failure rate, wide application, strong adaptability of raw materials, but the main technical and economic indicators are general.

Continuous charge furnace

In recent years, the continuous charging type electric furnace is one of the more furnace types newly put into operation. The biggest feature is that the scrap steel is continuously added in the smelting process, the furnace cover can be kept open, the energy input can be kept uninterrupted, the huge energy loss can be avoided, and the smoke and dust can not overflow. The high-temperature flue gas extracted from the furnace passes through the continuous charging tunnel, which also plays the role of preheating the scrap steel The consumption can be reduced by 30kwh-100kwh, and the molten pool is relatively stable, which reduces the huge noise and impact on the power grid produced by the traditional electric furnace during the electrode well penetration period, and the electrode consumption per ton of steel can be reduced by 0.1kg-0.3kg. In addition, in the smelting process, the molten pool is stable, the preheating temperature of scrap is generally not more than 400 ℃, the smelting cycle is shortened, the productivity is improved, the main technical and economic indicators are superior to the traditional electric furnace, but the one-time investment is higher than the traditional electric furnace.

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